Design and Analysis of Injection Moulding Die For Bottom Cover of Electrial Meter Body

DESIGN AND ANALYSIS OF INJECTION MOULDING
DIE FOR BOTTOM COVER OF ELECTRIAL METER

BODY
A
Dissertation work submitted to Jawaharlal Nehru Technological University
Anantapuramu for the Partial Fulfillment of the Requirements for the award of
degree of
MASTER OF ENGINEERING
IN
MECHANICAL ENGINEERING
(Specialization in PRODUCTION ENGINEERING AND ENGINEERING DESIGN )
Submitted by
K.NAGENDRA
ROLL NO: 139M1D9007
Under the guidance of

Dr. Y.SUJATHA, M.Tech , Ph.D.
(Associate Professor, Department of Mechanical Engineering)
DEPARTMENT OF MECHANICAL ENGINEERING

BHARATH EDUCATIONAL SOCIETYs GROUP OF INSTITUTIONS
GOLDEN VALLEY INTEGRATED CAMPUS
(FACULTY OF ENGINEERING)
(Affiliated to JNTUA,Anantapuramu)
Angallu,Madanapalli,Chittor(dist)-517325(A.P)
2013-2015
DEPARTMENT OF MECHANICAL ENGINEERING

BHARATH EDUCATIONAL SOCIETY GROUP OF INSTITUTIONS
(Approved by A.I.C.T.E, New Delhi Affiliated to JNTUA,Anantapuramu)
CERTIFICATE
This is to certify that project entitled DESIGN AND ANALYSIS OF INJECTION
MOULDING DIE FOR BOTTOM COVER OF ELECTRIAL METER BODY is the
work carried out by K.NAGENDRA, Roll No -139MID9007 at SRI SANTHA SIVAM
INDUSTRIES.,COIMBATORE, in partial fulfillment of the requirement for the award of
MASTER OF ENGINEERINGwith specialization in PRODUCTION ENGINEERING AND
ENGINEERING DESIGN at Bharath educational society group of institutions,madanapalli is
the record of bonafied work carried out by him under the guidance and supervision of
Dr.Y.SUJATHA,M.Tech, Ph.D Associate Professor of Mechanical Dept. of Mechanical
Engineering during the academic year 2013-2015.
The result embodied in this project report has not been submitted to any other
university/institute for the award of any degree
Project Guide
Head of Department
Dr.Y.SUJATHA, M.Tech, Ph.D

Associate Professor
Department of Mechanical Engg.
B.E.S.Group of institutions
Madanapalli.
Mr.G.Ramanjulu, M.Tech.
Assistant Professor
Department of Mechanical Engg.
B.E.S.Group of institutions
Madanapalli
DATE:-
EXTERNAL EXAMINAR
ACKNOWLEDGEMENTS
While bringing out this thesis to its final form, I came across a number of people whose
contributions in various ways helped my field of research and they deserve special thanks. It is
a pleasure to convey my gratitude to all of them.
We express our sincere thanks toDr.Y.SUJATHA, M.Tech, Ph.D. our beloved principal
for his encouragement and suggestions during our course of study
My deepest thanks to Dr.Y.SUJATHA, M.Tech, Ph.D Associate Professor, Department
of Mechanical Engineering, Golden valley integrated campus, for giving me an opportunity to
work under her guidance in this project and I specially acknowledge her for her advice,
supervision and the vital contribution as and when required during the project and in
preparation of thesis.
I am in debt and grateful to Mr.G.RAMANJULU, M.Tech Assistant Professor and
Head of the department, Mechanical Engineering, for his valuable support and help in
completing our project successfully.
We express our sincere thanks to project Co-ordinator Mr.G.RAMANJULU M.Tech.,
Assistant professor, for his valuable suggestions and guidance in completing the project work
successfully.
I would also like to thanks to Mr.MADASAMY, Senior Manager, SRI SANTHA SIVAM
INDUSTRIESPvt Ltd, COIMBATORE for giving me an opportunity to be a part of his team
during my training tenure. I am also sincerely grateful to Mr. RAMA KRISHNA, Mr. GOPAL
for helping us throughout the project.
Finally, we would like to express our sincere thanks to Faculty Members of M.E.Department
and Lab technicians, friends and family members one and all,which have helped us to complete
this work successfully.
K.NAGENDRA
139M1D9007
DECLARATION
I K.NAGENDRA bearing the Roll No:-139M1D9007, hereby declare that the project Report
entitled DESIGN AND ANALYSIS OF INJECTION MOULDING DIE FOR BOTTOM
COVER OF ELECTRIAL METER BODY done by me under the guidance of
Dr.SUJATHA, M.Tech, Ph.D, associate professor and I assure that this work is not copied and
submitted anywhere for the award of any degree.
DATE:
K.NAGENDRA
PLACE: Angallu
Roll No: 139M1D9007
ABSTRACT
Injection Molding is one of the most common methods in producing Plastic products for
many purposes ranging from a daily product to high-tech equipments. The Injection mould is
an assembly of parts containing an Impression and also some other accessories like Sprue,
Runner and Gate which is used to feed the material into the Impression and also an Ejector
assembly used to eject the component, which sticks on the core part due to contraction during
solidification stage.
The main theme of the project is to design, develop and analyze a mould for the bottom
cover of Meter Box. The material used for the component is Polycarbonate. The mould
made for this component is an Single Cavity Underfeed Runner less mould to accommodate the
customer order of 3lakhs/annum, in which the main cores, cavities along with side cores
actuated by Finger Cams, which are normally mounted at right angles to the mould axis
forming holes in the side face of a molding and also to form recess in the features embedded in
the component.
AUTODESK MOULD FLOW ADVISER is a Simulation Software used for analyzing
and optimizing the parameters like Gate location, Fill time, Injection velocity profile, melt
temperature, packing pressure, Cooling time, and Cycle time, areas of high volumetric
shrinkage(that could cause part warpage problems) etc were estimated. Three trials were made;
in first and second trials some defects were observed. Remedies were made for those defects on
trial and error basis. Finally optimum input values of process parameters like Injection time.
Injection Pressure, Cooling time nozzle temperature etc., are finalized for mass production.
CONTENTS
4
PRELIMINARIES
DEPARTMENT CERTIFICATE
ACKNOWLEDGEMENTS
ABSTRACT
CONTENTS
LIST OF FIGURES
LIST OF TABLES
i
ii
iv
v
vii
ix
1. INTRODUCTION
1.1 PROBLEM STATEMENT
1.2 OBJECTIVES
1.3. SOLUTION METHODOLOGY
1
2
3
3
2. LITERATURE REVIEW
2.1 PREPARATION OF POLYCARBONATE
2.2 ABOUT INJECTION MOULDING
2.3 ADVANTAGES OF INJECTION MOULDING
2.4 CYCLE OF OPERATIONS IN INJECTION MOLDING
2.5 INJECTION MOLDING MACHINE COMPONENTS
2.6 INJECTION MOLD
4
5
6
6-7
8-11
12-18
3. SIMULATION
3.1 INTRODUCTION
3.2 IMPORTING THE MODEL
3.3 MESH DENSITY SETTING
3.4 MESHING THE MODEL
3.5 MESH CLEAN UP
3.6 MATERIAL SELECTION
3.7 SELECTION OF BEST GATE LOCATION
3.8 COOLING CIRCUIT DESIGN
3.9 RUN THE ANALYSIS
3.10 SOLVING FILLING PROBLEMS
3.11 DETERMINATION OF PACKING PROFILE
3.12 ANALYSIS RESULTS
3.12.1 FILL TIME STUDY
3.12.2 PRESSURE AT V/P SWITCH OVER
3.12.3 TEMPERATURE AT FLOW FRONT
3.12.4 AIR TRAPS STUDY
3.12.5 WELD LINES STUDY
3.12.6 CYCLE TIME STUDY
4. DESIGN OF DIE
4.1 STUDY OF COMPONENT
4.2 STEP BY STEP PROCEDURE OF MOLD DESIGN
4.3 PROPERTIES OF POLYCARBONATE
5
19
20
20
21-22
23-25
26
26
27
27
27
28
29
29
30
31
32
33
33
34
35-36
37
4.4 ESTIMATION OF NUMBER OF CAVITIES

4.5 MACHINE SELECTION
4.5.1 SHOT WEIGHT CALCULATION
4.5.2 TONNAGE CALCULATIONS
4.5.3 INJECTION MOULDING MACHINE DETAILS
4.6 DESIGN OF DIE ELEMENTS
4.6.1 SELECTION OF PARTING SURFACE
4.6.2 DESIGN OF CORE & CAVITY INSERTS
4.6.3 DESIGN OF EJECTION SYSTEM
4.6.4 DESIGN OF GUIDE PILLAR
4.6.5 DESIGN OF FEED SYSTEM
4.6.6 COOLING SYSTEM DESIGN
4.7 MOULD BASE
4.8 ASSEMBLY OF MOULD BASE
37
38
38
38
38
39
39
40-42
43-44
45
46
47-49
50
51
5. DIE MATERIALS AND COST ESTIMATION

5.1 SELECTION OF MOULD MATERIALS
5.2 COST ESTIMATION
53-55
56-57
6. MOULD TRIAL
6.1 TRIAL-1
6.1.1 OBSERVATIONS
6.1.2 TROUBLE SHOOTING
6.2 TRAIL-2
6.3 POSSIBLE ISSUES FROM PRODUCTION PROCESS
58
59
59
60
61-62
7. CONCLUSION
8. REFERENCES
63
64
APPENDIX A: BILL OF MATERIALS

APPENDIX B: 2D ASSEMBLY AND DETAILED DRAWINGS OF INSERTS AND
MOLDBASE.
LIST OF FIGURES
FIGURE
NO:
Fig 1.1
Fig 2.1
Fig 2.2
Fig 2.3
Fig 2.4
Fig 2.5
Fig 2.6
Fig2.7
NAME OF THE FIGURE

3D Drawing of the component
Schematic diagram of Injection Molding Machine
Summary of elements of the Molding cycle
Different Zones in the Screw
Different types of clamps
Mold Daylight
Use of Hydraulic dia. to compare different Runner shapes
Different types of Gates
6
PAGE
NO:
2
5
7
8
10
11
14
15
Fig 2.8
Fig 2.9
Fig 2.10
Fig 3.1
Fig 3.2
Fig 3.3
Fig 3.4
Fig 3.5
Fig 3.6
Fig 3.7
Fig 3.8
Fig 3.9
Fig 3.10
Fig 3.11
Fig 3.12
Fig 3.13
Fig 3.14
Fig 3.15
Fig 3.16
Fig 4.1
Fig 4.2
Fig 4.3
Fig 4.4
Fig 4.5
Fig 4.6
Fig 4.7
Fig 4.8
Fig 4.9
Fig 4.10
Fig 4.11
Fig 4.12
Fig 6.1
Schematic diagram of basic Two-Plate Mold

Basic single impression Split Tool design
Different types of Molds
Simulation procedure flow chart
STL Format of the component
Types of meshing in mold flow
Meshed component
Aspect ratio diagnostic study
Mesh connectivity diagnostic study
Free edge connectivity diagnostic study
Suitable Gating location
Cooling quality comparison between different circuit designs
Volumetric shrinkage at the time of ejection
Fill time study
Injection pressure distribution on the part
Temperature at flow front
Air traps in the component
Weld lines study
Mold cycle time of the component
3D & 2D component drawing
Mold design procedure Flow chart
Core and cavity with parting surface
Core and cavity inserts
Core assembly
Cavity assembly
Ejector assembly
Sprue bush
Cooling system
Enthalpy curves for common materials
Plates used in mold assembly
Mould assembly
Barrel temperatures at different Zones
16
17
18
19
20
21
23
24
25
25
26
27
28
29
30
31
32
33
33
34
36
40
41
42
42
44
46
47
48
50
52
58
LIST OF TABLES
Table No.
Table 4.1
Table 4.2
Table 5.1
Table 5.2
Table 5.3
Table 5.4
Table 6.1
Table 6.2
Table 6.3
Table 6.4
Table 6.5
Table Name
Sprue sizes for polycarbonate material
Cooling hole dia standards
Composition of C-45 steel

Composition of H-13 steel
Composition of OHNS steel
Composition of EN-36 Steel
Processing parameters in 1st Trial
Barrel temperatures in 1st Trial
Processing parameters in 2nd Trial
Barrel temperature in 2nd Trial
Possible issues in injection molding process
Page No.
46
47
53
54
55
55
58
59
60
60
61-62

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DESIGN AND ANALYSIS OF INJECTION MOULDING

DIE FOR BOTTOM COVER OF ELECTRIAL METER

Under the guidance of

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Dr.Y.SUJATHA, M.Tech, Ph.D

Roll No: 139M1D9007

4.4 ESTIMATION OF NUMBER OF CAVITIES

5. DIE MATERIALS AND COST ESTIMATION

APPENDIX A: BILL OF MATERIALS

NAME OF THE FIGURE

Schematic diagram of basic Two-Plate Mold

Composition of C-45 steel

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